2005-09 Mustang Aluminum Radiator Installation Instructions

This lightweight Mustang aluminum radiator is a quick, and easy fix for a clogged, leaking, or damaged component! Whether you are daily driving, road racing, or drag racing, this SVE radiator is perfect for any 2005-2009 Mustang!

Adding a lightwieght aluminum radiator to your 2005-2009 Mustang is a great way to drop weight from your S197 and improve your cooling system efficiency. Installing an aluminum radiator in a 2005-2009 Mustang is a pretty easy step by step process. Follow along as customer Jeremy Howell walks you through his install!

Tools Needed:

  • Pliers
  • Flat head screwdriver
  • 8mm and 10mm sockets
  • Ratchet wrench with 4 inch extension
  • 8mm ratcheting wrench
  • Drain pan

How To Install 2005-2009 Mustang Aluminum Radiator

  1. Disconnect negative battery terminal
  2. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  3. Jack up the front end, put in jack stands
  4. Remove the intake, radiator cover, and the plastic cover underneath the bumper
  5. To remove the radiator cover, use the flat head screwdriver to lift up on the plastic screws to remove them
  6. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09) How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  7. Remove the plastic guard underneath the bumper by removing the screws holding it on with a pair of pliers
  8. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  9. Drain the coolant out of the radiator, using an allen wrench to remove the drain plug
  10. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09) How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  11. Crack open the coolant cap on the reservoir to act as a vent, and adjust the drain rate
  12. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  13. Squeeze the coolant hose to drain excess coolant
  14. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  15. Remove the small hose going from the top of the radiator to the coolant reservoir tank
  16. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  17. Remove the power steering fluid, and coolant tanks from the fan shroud
  18. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09) How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  19. Remove the upper/large coolant hose by using pliers, and a flat head screwdriver to loosen the clamp
  20. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  21. Tuck the hose out of the way
  22. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  23. Disconnect the fan power cable
  24. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  25. Remove the large/lower coolant hose from the radiator by using pliers, and a flat head screwdriver to loosen the clamp
  26. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  27. Remove the 2 plates on top holding the radiator in place by removing the 4 bolts holding them down
  28. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  29. Remove the 2 bolts located at the bottom of the radiator on each side
  30. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09) How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  31. Remove the 2 bolts located at the top of the radiator on each side by using a ratcheting wrench
  32. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  33. Carefully remove the radiator from the engine bay, being careful not to damage anything
  34. Once you have the radiator out, remove the fan shroud by removing the 2 bolts on each side
  35. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  36. Remove the 2 rubber grommets from the old radiator located at the bottom (you will need to reuse these on the new radiator)
  37. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  38. Remove the 2 screw studs from the old radiator using a pair of pliers, and install them on the new one
  39. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  40. Install the fan shroud assembly to the new radiator with the same 2 bolts you just removed
  41. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  42. Install the rubber grommets on the new radiator
  43. Lower the new radiator into the engine bay, being careful not to damage anything
  44. Reinstall the 2 top mounting plates
  45. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  46. Reconnect the coolant hoses
  47. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  48. Reconnect the fan power cable
  49. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  50. Reinstall the coolant, and power steering fluid tanks on the fan shroud
  51. Reinstall the intake, radiator cover, and the plastic cover underneath the bumper
  52. How To Install Aluminum Mustang Radiator (05-09) - How To Install Aluminum Mustang Radiator (05-09)
  53. Refill your Radiator with coolant, and check for any leaks *NOTE* You will have to add more coolant as the new radiator has a larger capacity!

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